Apparatus for partial oxidation of hydrocarbons



Junev 16, 1936. l` s. BURKE `APPARATUS FOR PARTIAL OXIDATION OF HYDROCARBONS 3 Sheets-Sheet l 1.o .mma msu... tkm

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A TTORNE y s. P. BURKE June `16, 1936.

APPARATUS FOR PARTIAL OXIDATION OF HYDROCARBONS Original Filed Jun ll, 1930 3 Sheets-Sheet 2 dommm LOU n@ ww wmv A u2/ moz H /NVENTO/e TEPH EN e BURKE.

Y E `N m T T 4A S. P. BURKE 2,044,665

A' PRATUS FOR PARTIAL OXIDATION OF HYDROCARBONS June 16, 1936.

Original Filed June ll, 1930 3 Sheets-Sheet 3 EPEE:

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NNN O NN INVENTOR TEPHEN P. BURKE ATTORNEY i Patented June 16, 1936 "APPARATUS, Fon rARTrAL oxinn'rion or nYDnocAaBoNs Stephen PQ Burke, Morgantown, W. Va., assignor i. to 4 Doherty `Research Company, New York,

N. Y., a corporation of Delaware l Original application June 11, 1930,` Serial'lJo.`

:460,319. Divided and this" application August 22, 1933,` SerialNo. 686,258 1 fsciaims. loi. 2342775v The present invention relatesto apparatus for carrying out exothermic .gaseousn reactions, and

particularly to apparatus adapted for the production of valuable intermediate partial oxidationvv ent invention areto provide an improved apparatus having a designadapted for controlling the temperature of exothermic gaseous reactions land `for confining the reaction to a definite, relatively- 5 products of gaseous or vaporized carbonaceousv small zone in the system; `to provide in an im- V5 substances such as hydrocarbons; mixtures of" proved manner for preventing substantial presc these with hydrogen and carbon monoxide, `such sure fluctuations in a system 'for the partial oxi-` as` are produced in coke oven plants, and similar dation of hydrocarbons and the like; to provide mixtures;y Itis` of `particular utility in connecl apparatus of the type referred to having provision l tion withthe homogeneous oxidation of hydroforthe rapid cooling'of the products of such re` 10 carbonsof the methane seriesforthe production 1 action to `insure their preservation; to provide of aldehydes and alcohols. c means for vso controlling these exothermic gaseous `'I'he invention` herein described was originally reactions as to assurea smoothly-progressing,

l disclosed in'my U. S. Patent 1,978,621 granted uniform reaction irrespective of appreciable varil5 October 30,"1934, led June 11, 1930, of which ations inthe temperature of the heating bath 15 thisjisa division. c i l k l surrounding the reaction chamber.; andto prol Manyprocesses forthe partial oxidation of hyvide apparatus adapted for the partial oxidation o drocarbonand the like arewell known,` in which of hydrocarbons suchas methane at temperatures o thejreacting materials inthe gaseous state are substantially below those normally suitable for `p remixed and passed under atmospheric or suthe purpose and at which temperatures substan- 20 peratmospheric pressure `through an elongated tially no thermal decomposition of the hydroreaction chamber immersed'in a constant tem# carbons or products of reaction would occur. perature heating bath.` The reaction products The present invention is based impart on the arc ledaway, and are subsequently treated to discovery that in the processing of gas mixtures t recover the normally vliquid components `thereof' of the character mentioned above,the temper- 25 by suitable condensation and absorption under ature at which the partial oxidation reaction is appropriate conditions.` AIn many instances the initiated is lowered as the diameter of the reaction reaction` chamber contains certain catalysts tube is increased, where thetotal rate of flow of l `adapted to facilitate the desired` reactions andto the gas mixture remains constant. `This may be w 39 retard other reactions tending to the'production explained as due to the inhibitory `inuence of 30 of complete oxidation products. 1 i the wall surface of the tubes which suppresses In theseprior processes in which reactiontubes the homogeneous reaction, (which is evidently of of uniform bore are employed, manydifliculties` the chain type),` bywhich the desired partial areencounteredin the proper control of the reoxidation products are" normally produced; or 3" actionsoccurring therein.` Especially is `this true *one may regard the phenomenon as being due to 35 where superatmcspheric pressures are employed, the difference in rate of heat transfer using tubes so` that as` the gaseous mixture isF heated to the of varying diameter. o reaction temperature, `considerable fluctuations It has been found possible so to select the' 40 of pressure occur in the system due tothe neces- `diameter and length `of tubing conducting the 4) o abovelftper centwwhen using a uniform bore sity for the employmentof a relatively long re- `actiontubeand tothe tendency for the reaction to successively propagate backward and forward l suitable temperature to initiate and support in the tube. Under certain conditions these pressure fluctuations maybecome so large as to pre vent the proper control of the conditions in the system. `As the percentage of oxygen present in the gas mixtureis increased, these pressure luc, tuations become more serious; and it has been found practically impossible to obtain satisfac` tory fresults employing oxygen concentrations tube.` Furthermorev lat the higher oxygen concentrations the formation of carbon taking place frequently causes blocking of `these reaction tubes.`

Among the more important objects of the pres` highly-heated gas mixture to the reaction chamber that all reaction isentirelysuppressed during o its passage therethrough, although the gas is at the desired partial oxidation reaction when the gas'rnixture subsequently flows into a short reaction chamber of suitably-increasedv cross section and having a larger ratio of volume to wall surface than said tubing. The reactionchamber g may be immersed in a heating bath maintained V Vat the same temperature as the gas entering therein, or it may be maintained at a substantially lower temperature for cooling the reaction chamber,l as will be hereinafter described. The desired reaction is thereby limited to the relatively small `volume of the small reaction chamber, and a smooth uniform reaction is obtained, which prevents pressure iiuctuations in the system and gives uniformity of results.

In carrying out partial oxidation reactions in the improved apparatus forming the invention, the hydrocarbons, or a suitable mixture thereof with a hydrogen-containing substance and/or a carbon oxide-containing substance, are vaporized where necessary, after which they are mixed with air, oxygen, or other oxygen-supplying gas in the usual way. This gas mixture is then passed through small tubes immersed in a constant temperature bath and maintained at the desired reaction temperature for a suitable length of time to permit the necessary heat transfer to the gases iiowing through the tubes. 'I'he preheated gases then ow into enlarged chambers which may form part of the said tube assembly or may be separate therefrom, in which chambers the desired reaction occurs suddenly. The gaseous reaction products formed then flow from these chambers through small metal tubes substantially of the size of those employed in preheating the gas mixture, which effects an immediate extinguishment of the reaction, due in part to heat transfer from the reacting gases, if such reaction has not been completed already. The reaction gases are then passed through a suitable train of condensers and separators by which the condensible vapors are condensed and are separated from the permanent gases. The latter, including any unreacted hydrocarbons, oxygen and the like, may then be mixed with fresh quantities of reactants and recycled in the process. Where the reaction is to be carried out under superatmospheric pressure, it is essential that means be employed for producing in the various lines the desired pressure, and that an expansionvalve or pressure relief valve bedisposed in the vapor oitake line leading from the reaction chamber either before or after the condensible vapors have been condensed.

In the accompanying drawings which illustrate certain preferred embodiments of the invention,-

Fig. 1 is a graphic representation of the relationship between reaction tube diameter and the reaction temperature, involving the principles underlying the invention;

Fig. 2 shows in somewhat diagrammatic manner an apparatus assembly illustrative of the preferred form of the invention;

Fig. 3 is an apparatus assembly illustrating a second modification ofthe invention; and

Fig. 4 is a vertical section of one form of chambered reaction tube.

It has been found that when a gaseous mixture capable of undergoing homogeneous thermal explosion (such for example as a mixture of hydrocarbon and oxygen which can be caused to react extremely rapidly and homogeneously to produce organic oxidation products) is led through a tube of uniform diameter which is heated externally, the temperature of the gas in the tube naturally increases as it proceeds through the tube, always tending to approach the temperature of the heating medium. It has been demonstrated beyond reasonable doubt that during the course of this heating a small amount of reaction occurs between the reactants. Since the reactions referred to are highly exothermic, a small amount of heat is liberated so that the temperature existing in the gas as it proceeds through the tube is slightly higher than would be the case for the same gases if no reaction occurred, However,

the amount of this reaction is so small that the ordinary analytical methods for gases will detect no change in the composition of the gas in the tube. When, however, the gas mixture in the course of its passage through the tube attains a certain temperature, which we may term the critical temperature (Tc), reaction suddenly occurs and proceeds to completion almost instantaneously. In the case of a mixture of hydrocarbons and oxygen, where hydrocarbons are in considerable excess, the oxygen content of the gas mixture which was unchanged in the course of passage through the tube up to a temperature just below the critical temperature suddenly completely disappears and is replaced by products of oxidation.

If we employ a liquid bath with a uniform temperature as the heating medium and immerse the tube through which the gas must be passed in the bath and slowly raise the temperature of the bath while measuring the oxygen content in the gases issuing from the tube, we find that the oxygen content remains unchanged as the temperature of the bath increases until a certain temperature is reached and then the oxygen disappears entirely. The curve (I) of Fig. 1, representing the variation of oxygen content with bath temperature is quite typical of hundreds of runs of this character that we have carried out. Now, if we replace the previous tube by another tube of exactly the same length but of larger diameter, and pass the same total quantity of gas mixture of the same initial composition through a larger tube at the same rate as employed in the previous case, and again plot the oxygen content of the issuing gases versus the temperature of the bath, we obtain a curve similar to curve 2 of Fig. 1. 'Ihe phenomenon in both cases is identical except that the use of the larger tube has lowered the temperature to which the bath must be raised in order to cause reaction to occur. If the diameter of the tube is made still larger, all other conditions remaining as just described, a curve similar to curve 3 is obtained. It will be observed that as the diameter of the tube increases the temperature to which the heating media must be brought tocause reaction steadily decreases. It is noteworthy that successively equal increments of tube diameter cause smaller and smaller reductions in the temperature to which the bath must be raised to cause reaction.

Now, it must be obvious that if we employ a small diameter tube, of diameter (D1), we may heat the bath to a temperature (Ts) (indicated on the graph) without having any appreciable reaction occur. If we now cause the gas to issue from the tube I, into the tube III having a diameter D3, reaction immediately ensues, because the bath is at a temperature in excess of that necessary to cause reaction in the tube of diameter D3. Therefore by building a reaction system composed of tubes of small diameter leading into chambers of large diameter and all maintained at a uniform temperature, it is possible, by proper control of the bath temperature, to preheat the reaction mixture in the smaller tubes to a temperature in excess of that required to cause reaction in the larger chamber without having any measurable reaction in the smaller tube. It is furthermore a fact that if the gas is caused to issue from the chambers into tubes of small diameter, either equal to or smaller than the inlet tubes, the reaction initiated in the chambers can in most cases be extinguished. This briefly describes the phenomena which forms the basis of accesos y thlsfpatentapplication. `It is subjectto modication, las will behereinafter pointedout. For example`,it is not necessary that the chamber` be at the same temperature as thepreheater c tubes; where a sufiiciently large increase of dlarneter is employedin passing iromthe preheater tube to the chamber, the chamber can `actually l `be surrounded by a bath `at a lower temperature 1 thanthat surrounding the preheater tubes.

In the drawings, numeral l0 designates an elongated closed vessel which may have its exterior wall surface heat-#insulated if desired. The vessel lll has a conical bottom l2, and is provided 1 pwith partitions I4, I6 which divide the vessel into `chambers I8, and 22.

. A plurality of elongated hollow metal `tubes 24, whichif desired may be made of catalytic material `such as nickel, are disposed inV parallel `longitudinally of the vessel Ill, passing through apertures in the partitions, IG-the 'said tubes., i. having their open,llower ends disposed within` fthe chamber 22.

Each tube 24 extends .through anlaperture in t the top of vessel I0, and has its open upperendy associated with a. collection head 26. A mid-portion of each ofthe tubes 24 positioned within the chamber I8 is o1' increaseddiameter `to `form an enlagedreactlon chamber 28.

. For heating a heat-transferring fluid and for circulating the samearound the tubes 24 in the l chambers I8 and` 28,--a heater `30 is provided,

f having a burner 32 and a heatingv coil 34, the rel aroundthe tubes in chamber 20,.

spective ends of the latter being connected to the upper and lower ends of chamber 28 through the conduits 36, 38, the last-mentioned conduit havl ing apump or the like 48 located therein. A plu-4 rality of baiiles 39 may 'if desired be arranged A vaporlzer 42 is connected with the upper and the lowerportions of chamber` I8 respectivelyby conduit 44 having therein pump 46, and by con-v duit 48. A condultl) connects conduits 38 and 48; and conduit 52 connects conduits 36 and 44.

`For introducingnirito the reaction lvesselthe i jnected with a source of hydrocarbons, asfor example natural gas,is in communication with the chamber 22 through the pipe 42; meter 64, compressor 66,` pipes68 `and 69, mixing valve i4 `and conduit l2.

If desired, the hydrocarbon gas may be pumped fromthecompres'sor 66 through an absorber i4 to e remove excess liquids present in the gas prior to being" sent `through the lvaporiaerf-or the" gas Y maybe pumped by the compressor direct into conduit 69 and thence to the vaporizer.

A valved air conduit i6, having a meter therein, leads froma source of air orother oxygen-` supplying gas under pressure such as the tank 14,

through the vaporizer 42 and communicates with "the mixingvalve lll.` Check valves 'i4 and 4l are tank les.

c preferably placedin conduits 'll and 'ladjacent the valve lll to prevent backflow through these conduits.- l? e e c The collection head `26 has `leading therefrom a vapor conduit 82 containing an expansion valve `sure pumps 100, H12, establishes communication between conduit @Zand a compressed gas storage A conduit 406 leads from tank `m4 tofraw gasconduit 69; and ajshort valve-con- .ing a scrubbi liquid such as water or glycerine Amay be immediately recycled under appropriate i l V I@ trolledconnection m8 permits direct communi-f cation of conduit 44 with the conduit W6. `In the operation of the apparatus shown in Fig. 2,:the-crudehydrocarbon or a mixture con# taining hydrocarbons such as natural gas is metered from line 6l) and aftersuitable `compression is passed throughlthe absorber i4.` The purified vapors are then passed through the coil in the vaporizer 42 where any remaining liquid isvaporired,- and the `vaporsare given an initial preheat.` Just prior'to the point of exit of the vapors from the vaporizer they are mixedwith l air or other oxygen-supplying gas whichmay have been preheated-if desired to the same temperature. `This gas mixture enters chamber I2 and thence flows into and is distributed uniformlywithin vthe relatively narrow preheating tubes 24 through whichit riiows at a predetermined rate;` being meanwhile heated to a high tempera,- ture by heat exchange with the heating iluid. such as fused sodium nitrate, or hot oil flowing around the tubes within the fluid circuit comprising the heater 30. The flow of vapors within the tubes 24 and the temperature ofthe heated fluidsurrounding the tubes is so adjusted that the v vapors are heated and maintained at a temperature below that at which the partial oxidation reaction isinitiated in preheatng tubes of the diameter employed, but above the temperature at which the said reaction will be initiated when the hot vapors iiow into the larger` diameter reaction chambers 28. As the hot vapors enter the 1 latter, the reaction is instantly initiated, and it progresses rapidly. The mixed vapors then ilow ,y atl once into the upper tube ends of smaller dl- `ameter, whichcause the reaction at once to be extinguished. `The heat generated by the reaction in the chambers 28 is conducted away from 4thechamber wallsv by the heat-transferring uid flowing in thelcircuit including chamber I8 and 40 thevaporizer 42, in the latter of which it is used to assist in heating indirectly the incoming gas mixture to be reacted. If desired, the said iluid owingjthrough chamber Hi` may be heated by passage throughconduits 48, 5l), .33, heatertll, 4 andfconduits 52 and 44.

The vaporized reaction mixture leaving the upv per ends of the-tubes 24 passes the expansion 1 valve 84where the pressure is reduced to substantially atmospheric pressure, and the vapors 50 which absorbs or `dissolves -certain valuable gas-` eous `partial oxidation products, the iixed gases thenpassing to gas storage at atmospheric or superatmospheric pressure; or the mixed gases pressure. Instead of having the expansion valve 84 in the conduit 82, it may be located in the -conduit leading from the,v condenser to the absorber. 98 and between the latterand the receiver Vlill; or it may be placed in the gas conduit 92.

propane, `butane and the like-the arrangement similar to that shown `in Fig. 2. In place of the type `of vaporizer shown in Fig. 2, there is provided a heat-insulated `column still 43 having the usual `dephleginating column `equipped with 'the perforated metal plates 4l. The hydrocarof thepreheating vessel and tubeassembly, is TQ' bon to be vaporized enters the mid-portion of the column through the pipe 69; and the gaseous hydrocarbon is withdrawn through the conduit 12 connected to the top of the still. For heating the contents of the still, a heating coil 49 or a jacket or both is provided. If desired, the ends of the heatimg coil may be connected respectively with the conduits 44 and 48. One large reaction chamber 29 is disposed within chamber I8, into which each of the tubes 24 extends,-in place of the individual reaction chambers 28 shown in Fig. 2. A plurality of relatively small tubes 25 extend from the reaction chamber 29 to the collection head 26.

A conduit 82 leads from the collection head 26 through a condenser 86 to a separator chamber ||0, having a valve-controlled draw-off line |I2 connected with the bottom thereof. A vapor line I I4 leads from the top of the separator chamber ||0 to a series of scrubbing vessels 6, II8, each having a valved draw-olf line in the bottom. A vapor conduit |20 leading from the top of the scrubber II8 has therein an expansion valve |22, adapted for holding the desired pressure on the system and for permitting escape from the latter of the scrubbed xed gases consisting mainly of nitrogen, hydrogen and carbon dioxide. A conduit |24 connects a mid-portion of the separator chamber I|0 with a tower |30 provided in its upper end with an aperture |32 normally controlled by a gas release valve comprising a valve seat |34 and a metal float |36 adapted to oat on the liquid hydrocarbon within the tower and to seat securely against the said valve seat when in its uppermost position to seal the interior of the tower |30 from the atmosphere. A conduit |38 leads from the lower part of 'the tower |30 through a high-pressure pump |40, into the pipe line 69.

The operation of the apparatus of Fig. 3 is similar in most respects to that of Fig. 2. A contro'led pressure is maintained on the iluid hydrocarbon mixture within the portion of the circuit comprising the line 69, vaporizer 43, preheater tubes 24, reaction chamber 29, and the vessels I|0, ||6, II8, and |30 by means of pumps 66 and |40.

In the form of the invention shown in Figs. 2 and 4, the reaction tube consists of a hollow body 2|0 of cold rolled steel or other suitable material adapted to withstand high pressures and temperatures. The body 2| 0 has a central aperture which is enlarged at one end of the said body to house a shouldered head or member 2I2 having a constricted bevelled mid-portion 2I4 adapted to seat against a sloping mid-portion 2|6 of the inner wall of the body ZID. A threaded gland and pressure-applying member 2H engages threads in the body 2|0 and functions to press the head 2|2 against the sloping mid-portion 2'I6 of the body 2|0.

A second apertured head 220, having a bevelled end'portion 222 and a threaded portion adjacent thereto adapted to engage threads on the inner surface of a sleeve 224 thereon, is adapted to have its bevelled end 222 pressingly engage a sloping internal shoulder within the body 2I0 by cooperation with a threaded gland nut 226, the latter engaging threads in the aperture in the body at the end thereof opposite that carrying the member 2H.

The lower end of the head 2|2 extends within the apertured body 2|0 to a point near but removed from a second constricted portion 221, so that an enclosed chamber 228 is formed between the adjacent ends of the heads 2|2 and 220 and the internal wall of the body 2I0 included therebetween. The chamber 228 is in communication with tubes 24 through relatively small central apertures 230, 232, in the respective heads, 2I2 and 220.

Instead of employing steel as the material of construction for the reaction tubes, various other metals and alloys may be used, which may or may not have catalytic properties with respect to the partial oxidation reaction. In this manner, nickel tubes may be utilized.

In carrying out partial oxidation of hydrocarbons in apparatus of the character described above, it invariably occurs that, while it is necessary to raise the heating bath and the gas mixture flowing therethrough to a given minimum temperature (varying with the conditions of operation) in order to initiate the desired reaction,

no reaction occurs at such temperature until the gas mixture flows into the enlarged reaction chamber at which point the said reaction occurs instantly and all or the major part of the oxygen reacts and is removed from the mixture. As soon as the desired reaction has been started, the entire system including the heating bath may be cooled down from to 100 C. or more depending upon the conditions of the reaction, the gases used, etc. without causing the reaction to cease. This may be described as a hysteresis eiect, and it makes possible uninterrupted operation, irrespective of relatively large iluctuations in the temperature of the heating bath surrounding the reaction chamber and the tubes conveying the gas mixture to the reaction chamber. Furthermore it has been found possible to carry out the reaction at appreciably lower temperatures than would be possible under similar conditions with reaction tubes of uniform diameter. This is especially important where gases such as methane which are highly resistant to the partial oxidation treatment are being processed, so that the temperatures employed need not be in the range of those effective for thermally decomposing the hydrocarbon to form free carbon so as to seriously reduce the yields of valuable partial oxidation products obtained.

For the purpose of illustrating certain applications of the invention the following examples are given; but it is to be understood that they are in no way to be regarded as limiting the scope of the invention beyond that which is set out in the accompanying claims.

A quantity of propane was vaporized and preheated to a temperature of approximately 150 to 160 C. and thereafter was mixed with air heated to the same temperature in proportions sufilcient to give the resultant mixture an oxygen concentration of 6.15%. This gas mixture was passed under a pressure of 750 lbs. per square inch through a 51-inch length of Shelby steel tubing of 31, inch inside diameter, during which time it was brought up to a reaction temperature of 339 C. No reaction whatever occurred under these conditions. From this tubing the mixture flowed into a steel reaction chamber of the type described above, having an inside diameter of 5%", and an internal length of H. 'Ihe fluid inlet end of the chamber was cone-shaped as shown in Fig. 4. The entering gas flowed through -the reaction tube at a. rate of 15.4 cubic it. per

hour; and the reaction within the chamber was completed in approximately .33 second after which the reaction mixture passed into an outlet pipe o1' Shelby tubing having an internal f io e diameter of. l'lyandlthe, reaction iwastpromptly extinguished As soonfas` the reaction had begun,`

thetemperatureof the heating `bathcould be reduced to as low as 291 C., Without substantially aecting either the rate i of` ythe partial oxidaytionf reaction" or `theycharacterq;ci the: products obtained. nAf temperaturen! 1/2 reaction of `339" C.

` waslrecorded."

whereas? astha temperature of` the` heating bath i `wt'aslincreased.to3.93.`this oxygen was'increasingly consumed 1 until 'at ltherlatter temperature all e ;of the, oxygen had: been `entirely consumed;` -At then higher` temperatures 4there was aA tendency for the percentage; of` .unsaturated hydrocarbons in the oil-going gases to increasepbutthe' per- .centageoi carbon monoxide did not vary mallterially.` `'I'hel acidity ofjthedrip recovered at the `lower temperaturesiwas somewhat higher than that 4obtained. at thezrhlgher u temperaturey-and `veryl `satisfactory :yields .of methanol l and aldehydes `were recovered-at thetlvarious points fwithinthe temperaturerange01.291" to 390 C. In

` asimilar `run in which. the reaction chamber had "zu an; internal diameter of 13/64:l inchf'and anhin-- ternalclengthof 26/64 inch,la propane air mixture containing percento! oxygen, maintainedat 750 lbs. perlsquare inch pressure. and flowing at 15.5. cu.' ft; per hour,` showed a temperature of halrgreaction of` 372! 1It `was possible to lower the temperature of the preheating bath to `345 C,

without extinguishingthereaction in theTreaction chamber.` although in such instancesthe ofE- going gases contained approximately ,1.9ypercent 5 of residual oxygenly.Toleffectcomplete""removal 45 reactionand that offcompletereactionfFurther# oftheoxygen a` temperature of395 C. wasnecessary.` e v e '1 Similar gas mixtures "containing" other -per` centages of oxygen .thank that recorded above give somewhat similar results. The higherthe `percentageofoxygen` present-in the original gas mixture; thelower wasithe temperature of half more; the permissible drop in" temperature of the' preheating 1 bath -below` thejtemperature y required for initiating the reaction; and which would still permit maintenance of the ,reaction,`" varied ldirectlywith the percentage ofeoxygen inthe gash mixture being treated.` j'

i '3 Thetemperaturespread or range ibetween'that" ofc half-reaction and `that"`of complete reactionV l decreasesas the oxygen-'content of the gas'mixture increases;` and at oxygen percentages of lltper cent andabovep these twovalues were ap- 1 proximately `the sanie.` "Oxygen"l percentages as high as "18 per'lcent ofthe gasmixtureff-equivay lent to"mixturesfcontaining p`er` cent propane l andy 90 percent"airfecouldfbeeffectively treat-` ed in accordance with-the present invention with-A v t out'- the formation of `e`arb n the system, and with resultant substantial yields or valuable'parf" tial oxidation i products l including methanol and formaldehyde,` although the most `satisfactory yields l of. these Vproducts were obtained with oxy- @l gen concentrations around 6 per cent.

. @To illustrate thefcharacter o1' thejresults' ob`` tained when fprocessing an oxidation-reslstant V gas normally requiring high temperatures vfor its `taining 6141 per cent i of foxygen, while under a pressure `of 750 lbs. per square inch, was flowed at a rate of approximately cubic feet per hour `through a length 5r `shaby steel tubing having vthechara'cter of thexreaction or the products :imed thereby, l N f anLinside'diameter of inch and was preheated tofa temperature of"468 C. preheated mix- `turelwas. then-ilowed into anjenlarged reaction products including methanol" and" formaldehyde. The reaction was'` extinguished by immediately passing the-ongoing gases through "another 10 length cfu?, `inch.inside"-diameter steel tubing.

-These oigoing Vgases contained approximately 2 per cent of residualoxygen, for the removal 1'olf which it was necessary to gotoa temperature of around 525HC. 4Orithel other hand, following 15 perature of the reaction l bath could be reduced to `as low as l 440 T'C. without substantially affecting d The extentl tofwhichthe temperature of `the reactlonsbathlcould belowered below the temperature ofj half lreaction (468 0.), without l lquenching the reaction may be varied by varying Generally thehigher the oxygen content ofrsuch mixture, Athe greater the spreadbetween the terne-` perature of half-reactionand that at'which` reaction" is extinguished within the' reaction chaml0 ben ..1 5. `1 Reference hasbeen heretofore" made inthis case to the temperature of half-reaction, by which is meant the temperature at which half of the oxygen'of the initial reaction mixture has been l5 usedup; This temperaturefis recorded because of Ithe fact thatithas been found diilicultrto ac` curately measure the temperature at which the reactionis initiated or that at which it is complete, while an accurate measurement of the temper'ature vatwhich half of'the oxygenhasjbeen consumed' can readily .be obtained.

11n carrying out partial oxidation the apparatus assembly ofFig. 12; a' vmixture of hydrocarbons', `such asnatural gas may bejflowedthrough the preheating coil ll under the desired pressure induced bythe compressor 66,` and anycondensed liquids are removed ineth'e kabsorber 14'. j The` naturalgas` is then mixed in themixing valve 10 with air which has been `pre-heatedto the same .than that "ofthe heat-transferring vfluid in chamf` ber 20. "The gaseous products of the reaction then lilowthroug'h the smalltubes 24, header; 2li and through thefexpansion valyeslwhere the pressure is` reduced substantially" at; atmospheric pressure. `'The gasesthen flow through the con-` denser 86 where fcondensible vapors are condensed and ilowifintov the receiying vessel 88]. The re, maining gases ilow into the separator BIJ below the levelfoffthe liquid such` as water therein,V which absorbs therefrommthe constituents con`y densibler or soluble thereinLj-the "remaining `or `permanent gases being` drawn off through line 92 to gas storage tank 96, or'they may be pumped direct by means of the booster pumps |00 and |02 75 e temperature whilepassing through pipe 16. l

gas mixture then flows into the smallesteel tubes to the pressure storage cylinder IM. These gases containing some unreacted hydrocarbons and, in some instances, small amounts of oxygen, may then be recirculated in a second cycle of operation, after being fortified with suitable amounts of natural gas or other hydrocarbons through the line 69. The temperature of the preheating baths may be maintained in part by circulation of the preheating fluid through one or more heaters 30, and in'part by the heat of reaction transmitted thereto by the reacting gases through the walls of the reaction vessels 28. Other suitable methods for maintaining the desired bath temperatures will readily suggest themselves and may be employed.

Instead of using a plurality of relatively small reaction chambers in the manner shown in Fig. 2, a single large reaction chamber may be employed into which the various small tubes conveying the incoming preheated gas mixtures may feed the latter. This arrangement does not permit the effective removal of the heat of reaction of the gas mixture to the same degree as the arrangement shown in Fig. 2. Fig. 3 illustrates the preferred arrangement where propane or other gas which is liqueflable under the conditions of use in the process is to be employed. In the operation of the process when using the apparatus of Fig. 3, the gaseous or vaporlzed hydrocarbons and air or other oxygen-supplyinggas are mixed in the vaporizer and are pre-heated in the small tubes 24 before entering this single large reaction chamber 29. 'I'he off-coming vapors ow through the collection head and conduit 82 to a condenser, and thence into the separator H0 in which the condensed liquid is permitted to settle and stratify, thus forming a loweraqueous layer containing liquid partial oxidation products, and an upper oily layercomposed of unreacted hydrocarbons such as propane that are liquid at the temperatures and pressures maintained in the separators. This latter layer contains some of the aqueous products Yin suspension therein, and also some of the gaseous reaction products which are soluble in the propane at the pressures used. 'Ihe aqueous reaction products are withdrawn from the separator and subjected to the usual type of renning process for recovering the aldehydes, alcohols, and other materials therein. 'I'he propane is withdrawn either continuously or intermittently through conduit |24 and led to the tower'l. In the latter the dissolved gases are permitted to escape from the hydrocarbons to the atmosphere. The float valve |36 functions to prevent overflow and loss ofthe liquid hydrocarbon should the latter flow into the tower |30 at a faster rate than the degassed liquid is pumped therefrom into the line `89 for recycling in the process.

The fixed gases flow from the separator I|0 through conduit vI Il into the scrubber I I6 which contains water or an aqueous solution such as glycerine, where any occluded aqueous partial oxidation products not recovered in the separator are removed therefrom, and may be withdrawn through theA valved line in the bottom. `The remaining gases then flow through conduit I I1 into the oil scrubber H8 containing an oil such as kerosene, in which oil, any residual propane or other hydrocarbon is absorbed and may be removed therefrom by suitable treatment after withdrawal of the oil through the bottom valved conduit. The residual gases flow from the oil scrubber past the expansion valve |22 to suitable storage, or may be discharged to the open air.

In this modification of the invention, the expansion valve is so placed that a major portion of the heat of reaction is'removed from the gases flowing from the reaction chamber prior to the reduction of the pressure to atmospheric pres- I sure.

While in the examples given, hydrocarbons vand air have been the respective gases employed, it will be obvious that the apparatus is adapted for the treatment of mixtures of hydrocarbons with chlorinating agents, oxygen, and various other oxygen-supplying gases whereby reactions of the well-known thermal explosion type are initiated. Furthermore it is possible to operate at atmospheric 'pressure or at various other pressures above orbelow atmospheric instead of at the pressures specifically 1 mentioned herein. There is a tendency for the methanol content of the gases to increase with increase in pressure, Vand particularly at pressure above 250 pounds per square inch.

The invention is well adapted for use in connection with homogeneous catalysts such as the ,nitrogen oxides, methyl ether, and the like.

Thesemay be introduced into the gas stream just 28 before the latter enters the reaction chamber, or at some point within the preheater. In some instances the reaction chamber may be constructed of a particular material having catalytic properties adapted to promote the desired partial 30 oxidation reactions. Furthermore the inner surface of the reaction chamber may be coated with a suitable catalytic material such as nickel. In the latter case this may be done by introducing some of the catalyst into the gas stream before 35 it enters the reaction chamber.` For instance, nickel carbonyl may be introduced into the gas mixture and flowed into the reaction chamber while heating the latter at temperatures suitable for decomposing the nickel carbonyl, whereby the 40 walls of the chamber are plated or coated with nickel.

The invention is susceptible to modification within the scope of the appended claims.

I claim: f

1. Apparatus adapted for carrying out exothermic gaseous reactions comprising, in communicably connected series, a heat interchanger, at least one elongated,pressure-resistant preheating tube, a relatively short reaction chamber, 60 an elongated reaction quenching and cooling tube, the said reaction chamber having a smaller ratio of wall surface to volume than that of the said preheating and cooling tubes communicating therewith; a heater, means for circulating a heat 55 transferring fluid through the heater and in heat exchange relation with the preheating tube, and means for circulating a second heat transferring fluid in heat exchange relation with the reaction chamber and through the heat interchanger.

2. Apparatus adapted for carrying out exothermic gaseous reactions comprising. at least one elongated pressure-resistant preheating tube, a relatively. short reaction chamber in communication with the discharge end of the preheating as tube, the said reaction chamber having a smaller ratio of wall surface to volume than that of the said preheating tube communicating therewith,

a heater, means for circulating a high temperature heat transferring fluid through said heater 70 and in heat exchange relation with the preheating tube, a heat exchanger, and independent means for circulating a second heat transferring fluid through the heat exchanger and in heat exchange relation with the reaction chamber.

i v:3,044,666 a t transferring nula through the heater end 1n heet' f 3.`Apparatus` adapted for `carrying out exothermic gaseous reactions comprising. in communicably connected series, at least one. elonr gated pressure-resistant preheatlngtube,` 'a relatively short reaction chamber, andat least one elongated pressure-resistant reaction quenching and cooling tube, thesaid reaction chamber hav- .i-ng a smaller ratio of `wall surface to volume then that ofthe seid preheeting tube and, e001- ing tube communicating therewith; a heater,

means for circulating a high temperature heat portion of the cooling tube leading fromthe end of the reaction chamber opposite to that first mentioned;

s'rEPImN P. BURKE. 

